Method and apparatus for continuously transforming a dispersion of a rubbery material into a sheet



W. F. BIXBY METHOD AND APPARATUS FOR CONTINUOUSLY TRANSFORMING A DISPERSION OF A RUBBERY .MATERIAL INTO A SHEET Original Filed May 9, 1942 July 6, i948.

-.- 17 llr Nm. .NAI @w QN wwf.. uw i 1 .QQ m\ .wwwmwm mi wmml. mw f%% m.%\ A o o Nw. o i Y Wm. u, NY MUN u Y d llllll Il PS lill Ish, lll |l| Y H| Lf H, I. A. ,H|||I|||||l www lhlllm ||H| w ||I l HI|II|IIIPHHAI H l|||||||H|||..l|. v H|||| l. @m mw u a@ mw WW QM @N QN n@ mm, Rnd @MYW 5% N wmd KMJ @N WWHN mY .m\ l Q WNJ|1 RWA() Patented July 6, 1948 METHOD AND APPARATUS FOR CONTINU- OUSLY TRANSFORMING A DSPERSION OF A RUBBERY MATERIALINTO A SHEET Willard F. Bixby, Cleveland; Ohio, assigner to They B. F. Goodrich Company, New York, N. Y., a corporation of New York` Original' application May4 9, 1942, Serial No. 442,350. Divided and this application October 1, 1945, Serial No. 619,581v

13 Claims.

Thisinvention relates to amethod for continuously, transforming. a dispersion of a rubbery material into ay sheet and to apparatus infwhich the method may bercarried out.A

The commercial methods of coagulating Hevea latex have been in general batch processes in whichlthe .rubber `has been coagulated in shallow pans andthen sheeted. Problems have arisen in connection with-the coagulation and washing of synthetic rubberlatices which kare not AencounteredwhenHevea latex isfemployed, largely due to the amount and kind of emulsifyingV agent presentand to theiact thatthe particle size of synthetic rubber latex is ordinarily only from one-tenth to one-third as great as the particle sizeof Hevea latex.

It is anobjectof thisinvention to provide apparatus-and a method .for the 4co-ntinuous coagulation, washing, anddrying of a dispersion of a robbery` material to form a uniformsheet. It is afurther object to provide a. method whereby a dispersion of a rubberyk material can be coagulated to form a slurry containing small'rubbery particles. It is a. further object to provide a method for preventing the agglomeration of the small rubbery particles formed. It is a further object to provide method for decreasing the size of large particles in a slurry of rubbery particles. It is a further object to provide a method of washing rubbery particles on a pervious carrier without disturbing their position. It is a further object to provide amethod for pressingrubbery particles into a sheet upon. a pervious carrier without causing the adhesion of the particles to the carrier. Further objects of the invention Will b e apparent fromthe following detailed descriptionof the apparatus and a continuous method lfor transforming a specific synthetic rubber latex into a sheet.

Much of the difficulty which ha-s heretofore attended attempts continuously to coagulate and sheet` dispersions of rubbery materials has been experienced in attempts to wash the coagulum free from theemulsifying agent and other materials present during the polymerization which are not desired-in the product. I have now discovered that the difliculties are largely avoided if s, dispersion of a rubbery material is coagulated to form an aqueous slurry of uniform, small, rubb'ery crumbs, vthe slurry is deposited upon a pervious `carrier to form a layer of crumbs, andthe layer ofV crumbs is washed on the carrier without substantially disturbing the position of the ormnbs:beforey the-layer is pressed into a sheet,

'dewatered and' dried;

The methodzof this invention may bev applied to-.any dispersione ofrubbery materials. Emulsion polymers of butadienes1,3 such as. butafdiene-L. isoprene,v piperylene, 2,3-dimethy1- butadiene or 2-chlorobutadiene-L3 or copolymers of butadiene-1,3. with monoethylenic monomers copolymerizable therewith in aqueous. emulsion suchas.acrylonitrile, styrene, methyl methacry* late, or methyvljsopropenyl ketone, prepared in alkaline emulsionswithv a soap such as -sodium myristate, sodium palmitate,. sodium oleate, or a mixture: off soaps are preferredmaterials since they can be` readilycoagulated to form a slurry ofnmiform.smalllcrumbsless than 1 mm. indiameter-by adding` a saltv to the latex andithen lou/teringv the pHto effectthe coagulation. Butadiened copolymers prepared'in the presence of acid-stable. emulsifying agents such as sodium lauryl sulfate may bel coagulated in thewform of uniform, smallcrumbs by. merely. adding a salt solution to the latex with stirring. Likewise, Hevea latex orarticial dispersionsy of natural or reclaimed-.rubber may beemployed if` they are compounded-,in such amanner that they. can=be coagulated to fo-rin a slurry of uniform, small crumbs.

The inventionmay befbetter understoodfrom the accompanying drawing of which Figs. la;l b and :e 'illustrate aparatus suitable forcoagulating, washing; sheetinganddrying.dispersions of rubberymaterials.

Referring to the'dra-Wing, the formation ofthe slurry of small, rubbery` crumbs is performed in tanks# Ill,v II and I2. Two storage tanks I3'and I/lffor brine and latex respectively lead into tank l0; the inlet trombrine tank I3 extending through thetankand into the inlet of an open impeller centrifugalpump t5. Conduit Ifleads fromthe pump I5 to a. cross valve I'I which .distributes the contents of tank i'between conduit I8 leading back into the tankV lil-'and conduit I g/leading'in-to the coagulating tank- I I. The treatedlatex flowing'from the conduit lll'isintermingled with-fresh latex flowing'fromfstorage tank Hl through conduitim,L andfalls into tank I0 which is provided with astirrer 21|. Coag-ulating tank lI-al'so'has an `outletfleading` into another open impeller centriiug-a-lpumpZZ yfrom which acondu-it 23 leads to cross valve-24 which divides the contents-ofthe cond-uit between tanks II and I2 through conduits :25?fand'26. The contents of conduit 25 are intermingled `with coagulant solution flowing from supply tankZl through conduit 28 andfall into tank II` which is-provided with a stirrerY 29. Tank- Il2=f is also--provided-With a stirrer- 30,y and 54, 54 consisting of Wire brushes.

has an outlet leading into another open impeller centrifugal pump 3| which discharges through conduit 32 into cross valve 33 dividing the contents between conduits 34 and 35. Thecontents of conduit 3 4 are intermingled with` the pl-l-controlling material of supply tank 36, discharged through conduit S1, and returned to tank l2. Conduit 35 leads into a mechanical di-sintegrating device comprising a stator 38 provided with inwardly-extending knives 39 and a rotor 40 providedl with outwardly-extending knives 4|. The conduit (i2 leads into the head-box $3 provided with a distributing roll 44 andthe weirs 45, 46. An apron 4l extends from the head box to the sheet-forming portion of the apparatus.

The sheet-forming portion of the apparatus consists of an endless wire mesh screen B passing around driven rolls 5| and 52 and provided with tensioning rolls 53, 53 and cleaning rolls Spray pipes 56, 56 also assistin keeping the screen clean. Water for washing the material on the screen is sprayed from the nozzles `5`|, 51 in pipe 58 onto the spreader pans 59, 59, from whence it flows uponthe material on the screen. The force of the spray is broken by the spreader pans 59, 59. lPieces of cloth 6i) placed on the lower edges of the spreader pans, or screens (not shown) placed on the spreader pans at right angles to the direction of flow of th'e water may be employed to prevent channeling and assist in obtaining an even distribution' of water. The washing means below the screen islocated further along in the direction of motionv of the screen than the washing means above the screen and consists of the nozzles 6|, 6| in the pipe S2. The screen passes under a dandy roll-63 Awhich is a hollow wire screen roll containing the spray 64, under the rubber press rolls 65, 65 after each of which is located washing means consisting of nozzles 68, 66 in a pipe 61 .above the screen and nozzles 68, 68 in pipe 69 located under the screen. The screen then passes under the rubber couch roll 70 whose center of rotation is slightly nearer the head box than the center of rotation of the driving roll 52.

Further pressing of the material leaving the screen is achieved by passing the material on the felt i5 passing' around the rolls 'I6 and Tl and the tensioning rolls 88, 88. The material 0n the felt is dewatered by passing between roll 89 and driven roll 90, roll 89 being a wooden roll land roll 9U being a suction roll, and by passing between the solid metal rolls 9| and 92. HThe material passes from the felt '|5 to the conveyor |88 driven by rolls and ||l2 which. passes through an oven |03 provided with hot air ducts it, iilft above and `below the conveyor. In a separate section of the oven, cold air ducts |85, |05 are placed above and below the conveyor. y The cooled material iinally passes from thei conveyor to wind-up roll |86.

The operation of the apparatus will be eX- plained by describing the continuous coagulation, washing, sheeting, dewatering, and drying of a synthetic rubber latex prepared by the emulsion copolymerization of 75 parts by weight of butadi` ene and 25 parts of styrene in the presence of 5 parts of soap (sodium oleate). The latex contained about 30% by weight of synthetic rubber.

Such a latex is rather unstable and can be i pumped only with diiculty. The iirst step in the operations is accordingly astabilizing operation whereby the particle size oi the synthetic rubber in the latex is increased while the particles still, remain dispersed in the water. The stabilizing is 4 conveniently accomplished by the addition to the latex of a water-soluble salt of a water-soluble acid, ordinarily sodium chloride or other salt which ionizes `to yield monovalent cations, in an amount sufiicientv to increase the particle size of the latex but insufficient to cause irreversible coagulation as disclosed in the copending application of Edward A. Willson, Serial No. 442,368, now abandoned, filed May 9, 1942. The amount of s-alt employed will depend upon the concentration and nature of the latex, the concentration and nature of the emulsifying agent in the latex, the pH of the latex, and the particular salt added. For a synthetic rubber latex containing between 2G and 40% by weight of a copolymer of butadiene and styrene and from 3 to 8% based on th'e rubber of soap, from 10 to 50% by weight of sodium chloride based on the rubber are ordinarily required to achieve the desired increase in stability. Latices in which the soap is less soluble, as, for instance, those resulting from the emulsion copolymerization of butadiene and acrylonitrile, require smaller amounts of salt than latices such as those resulting from the copolymerization oi butadiene and styrene in which the soap is quite soluble. The salt is added in the form of an aqueous solution, preferably containing from 5 .to 15% oi' salt. Although more concentrated and even saturated salt solutions may be employed,

it is more diiicult to avoid the presence of highK local conoentrationsof salt than when dilute solutions are used.

When the apparatus herein described is in operation, brine is contained in storage tank I3, latex is contained in storage tank Ill, and tank |i contains stabilized latex. Operations are ordinarily started by partially filling the tank i0 with water, then starting the ow of brine from tank i3. The pump is then started, and when the proper concentration of brine in tank l0 has been reached, the latex flow from tank I4 is started. After a time, the system cornes to equilibrium. The addition of the salt increases the size and decreases the surface of the rubbery particles with the result that the stability of the latex is increased without any increase in the yamount of emulsifying agent. The latex prior to the addition of the salt has an average particle size of only about 6.1 or 0.2 micron, but the stabilized latex has an average particle size of about 0.4 micron. The brine from tank I3 is preferably introduced into the stabilized latex at or near the entrance to the centrifugal pump I5, so that an intimate admixture will occur soon after addition of the brine and high local concentrations of salt will be prevented. The stabilized latex is then recycled through conduits I6 and i8 and led back into tank l0." Supply tank ht is lled with latex which is added in suiicient volume to keep the supply of latex in tank substantially constant. Im-

pingement mixing is obtained by contacting the streams of untreated and turbulently-lowing salttreated latex issuing from conduits 20 and I8 respectively, the velocity and amount of the salttreatedy latex being considerably greater than the velocity and amount of the untreated latex. Other means of introducing a relatively small amount of untreated latex into the turbulentlyflowing salt-treated latex may be employed. Thus conduit 2! may lead directly into conduit I8, and the treated latex flowing turbulently through the conduit may entrain the untreated latex and then pass into the tank I0. If desired, the pipes V2|) and |8 can discharge beneath the surface of the liquid in tank lll, or can lead into a/common -pipe which discharges beneathl the surface.

-Although satisfactory results are vobtained by adding a simple `salt solution to stabilize the latex, additional advantages are 'obtained by including -a buffer such as sodium bicarbonate, sodium acetate, sodium tetraborate or sodium acid phosphate "in ithe brine solution in amounts considerably smaller than the salt. It is desirable in some cases Vat a later stage in .the process to have present a 4protective agent the nature and function of which vWill be hereafter described. The protective agent is preferably added prior to the coagulation, al-

=though it may be added at a later stage in the process, and inclusion of the protective-agent in the brine is a convenient method of addition.

:For a latex of the composition herein described,

the brine solution may contain by Weight of a -salt such as sodium chloride, 1% of a buffer such as sodium bicarbonate, and 0.05 to 0.3% of aprotective agent such as sulfonated rosin and/ or sulf'fonated pine oil. -performed by adding the brine and the latex at Va vrate of 2 gallons per minute through conduit The mixing may be eiiiciently 1/4 in internal diameter, recirculating the latex through conduit Ir at a rate of 150 gallons per V'minuta diverting 4 gallons per minute through conduit i3, and recirculating 146 gallons per min- Vute of stabilized-latex through conduit EB which -may be about 2 in internal diameter.

The coagulation is effected in tank il which, Aat the sta-rt of the proc-ess is filled with coagulated latex slurry or Water. The salt-treated latex entering the tank is-mixed with the coagulated latex having a pl-I of about 8.5. The contents of the tank are pumped at the rate of 150 gallons per minute through conduit 23, with 5 gallons per kminute being sen-t through conduit 2G and the re- 'mainder passing through conduit 25 and contacting the coagulan-t flowing from supply tank 21 through conduit 2=E at a rate of 1 gallon per minute. Again, the high velocity and quantity of flow of the slurry issuing from pipe 25 as compared 'with the ooagulant issuing from pipe 28 is im- `Portant.

The streams interrningle, and then fall into the coagulating tank il. In this case the coagulant is 0.25% sulfuric acid, although acetic acid or other ooagulants in suitable concentrations may also be employed. The same modifications in the mixing of the coagulant with a relatively large volume of turbulently-flovving slurry may -be employed as in the mixing of the un- "treated lat-ex with the salt-t-reated latex.

l1a small-amount of uncoagulated salt-treated latex is mixed with a small stream of coagulant in such a manner that a high local concentration of 'either coagulant or uncoagulated latex is avoided. The particles thus formed range between 0.2 and 0.5 mm. in diameter. After the synthetic rubber has been coagulated in theiform of uniform small particles, it is desirable to have present a protective agent to keep 'them from elumping together `toform larger particles. k'ment is such .that the emulsifying agent is im- If the subsequent treatmobilized or destroyed, addi-tional protective agent should be added. The protective agent may 4.be-any of the acid-stable wetting agents suchas long chain alkyl sulfates including sodiumlauryl sulfate, alkyl *arylv sulfonatessuchasJ sodium isopropyl naphthalene sulfonate, aromatic or'long- `:chain alkyl-compounds containin-g'a polyalkoxy chain terminating in a hydroxyl group, orslfonated terpenes'such as sulfonated r-osin ory pine oil, or protective colloids such vas animal glue,l gela'tin, dextrin, starch, colloidal clay, etc. '-Th'ese protective agents areadded to the latex'- beforecoagulation or to the slurry after coagulation in=an amount sufficient to prevent theagglomeration of lthe rubbery crumbs.

The details of the next step in the process Vary depending upon whether fatty acid-is desired in the product or not. If' it is desired to prepare synthetic rubber containing a substantial amount of `fatty acid, the pI-I of the slurry of rubbery crumbs is reduced 'to about 4 to convert the soap into 'fatty acid. This may be done in tank l2, the

slurry being recirculated a-t a rate of gallons per minute, 5.6 gallons of slurry being diverted through pipe 35 and .the remainder Apassing through pipe -34 and interming-ling with dilute acid being fed from tank`3 through pipe 31 ata rate of 0.6 gallon per minute. A concentration-of sulfuric acid of l or 2% is ordinarily suiicientto maintain the pl-I of the slurry a-t 4 or below. During this process, the rubbery crumbs grow to a size of from 0.5 to 0.8 mm.

If the presence of-fatty acid is not: desired Ain the final product, the aqueous slur-ry may be Washed in tank l2'2to extract as much of the soap as possible from the rubber particles. Thisw-ashing opera-tion is preferably performed at a pI-I of from-8 to l0. A solution of sodiumlhydroxi'de is added from tank 3G of a proper concentration to maintain the pH at the desired level. Additional tanks may be employed to Wash the crumbs if desired.

If desired, the concentration of acid being fed from :tank 2T can be high yenough' both'to coagulate the latex and to convert the desired amount of soap into fatty acid. It has been found, how ever, that a somewhat more uniform slurry may be obtained by carrying on the coagulation and conversion of the soap as separate steps in the process.

The-stabilization and coagulation of thedispersions of rubbery material in separate steps as shown above assists in the formation of a slurry of uniform, finely-divided rubbery crumbs, but-it is not essential that these steps be carried on separately. Thus thesynthetic rubber latex may vbe caused to entrain streams of salt solution and ccagulant solution either successively or simultaneously While flowing turbulently through a conduit. Also, a turbulently-flowing slurry may be'caused to entrain streams of uncoagulated latex and coagulant solution either successively or simultaneously. In another modificatioma Aturbulent-.ly-fiovving stream of `synthetic rubber latex encounters jets of salt solution and coagulant solution as it is falling from a conduit into a container. Other means adapted to convert continuously-a dispersion of a rubbery material :a Bauer mill, 'a Charlotte mill, or a J ordan engine.

weirs 45 and 46 and onto the screen 50.

AiJordan engine is shown in a simplified form in .the drawing, but other mechanical disintegrators employing sets of knives or corrugated surfaces between which the crumbs are disintegrated may be employed. It is highly desirable that a protective agent be included in the slurry before it is fed through a mechanical disintegrator. If the coagulation has been effected in such a manner that the slurry consists of uniform particles not over about 1 mm. in diameter, however, there is no necessity for employing a mechanical disintegrator.

The slurry is next led into head box 43 provided with a distributing roll 44 which aids in maintaining an even distribution of the crumbs in the slurry and assists in preventing further increase in particle size. The distributing roll herein shown consists of a cylindrical sheet metal member containing "A," holes on I/z centers, although any other kind of perforated roll may be employed. l

From the head box, the slurry passes over the This screen may be made of any desired pervious material. A '70 mesh screen made of Duraloy wire (a nickel-copper alloy) has been found to be very satisfactory for the purpose since it is acidresistant, and any synthetic rubber adhering to the screen can be burned therefrom taking proper precautions not to harm the wire. The crumbs form a porous layer upon the screen, and the washing process is then started. The impact of water being sprayed directly on the crumbs at this stage is apt to disturb the layer, so the water is preferably sprayed on a curved piece of metal 59 from which a stream of Water flows upon the moving layer of crumbs while progressing at about the same velocity and in approximately the same direction. The force of the flow may be further broken by attaching a piece of woven or felted fibrous material 6D to the lower end of the trough 59. At this stage of the process, it is advantageous to employ hot wash water. The water may be at any desired temperature as from 1Z0-200 F. In the particular operation herein described the wash water was heated to about 140 F.

After several washes from the top of the screen, the synthetic rubber particles have cohered to such an extent that they can be washed from beneath the screen without disturbing their position. This is effected by the sprays of hot water from the nozzles Bl, 6l shown in the drawing. The sheet then passes under the dandy roll 53, which is a hollow metal roll having a perforated face allowing the free passage of water into the interior of the roll and preventing the formation of a bank of water in the bite of the roll which might break the sheet. The sheet then passes under the rubber press roll B5, and is then washed by a jet of cold water from nozzle B6 directed onto the sheet at the point where the pressure of the roll is removed. The sheet is in a distorted condition at this point, and absorbs water more readily than when the strains imparted to it by the roll have disappeared. The use of cold water at this point is a very important factor in the formation of a sheet of'sufhcient strength to permit the removal of the sheet from the screen.

lAlthough reduction of the temperature to 32 F.

is not necessary, the water should be as cold as economically feasible, and it is very desirable that the temperature be below at least 100 F. Water of a temperature of about 60 F. was employed in the operations herein described. After passing under the roll 65, a jet of cold water, air, or other uid from nozzle 68 underneath the screen lifts the sheet momentarily from the screen to prevent the sheet from permanently sticking thereto. The sheet is then passed under another rubber press roll 65, is washed with cold water from nozzle 66 directed at the bite of the roll, and is again lifted from the roll by another spray of cold water, air, or other fluid before passing under the next roll. These pressing, washing, and lifting operations may be repeated any desired number of times. The sheet then passes under a top couch roll 10 centered slightly ahead of the driving roll 52.

The continuous sheet now contains about of water on a dry rubber basis, and is removed from the screen and to a carrier i5 which is preferably constructed of pervious, napless fibrous material such as a napless open-woven wool fabric. The sheet passes between press roll 89 and suction roll B0 where 50% of the water is removed, and then through press rolls 9| and 92 where 25% more of the original Water is removed. These values apply to the specific synthetic rubber employed in this experiment, but they may vary widely with the type of synthetic rubber and the amount of fatty acid left in the synthetic rubber. The sheet then is transferred onto another conveyor 400, which should support and carry the sheet without contacting it over any greater area than necessary, and is carried through a hot air drying oven 103. The hot air blows upon the top and bottom of the sheet through ducts 104, |04, and may be of any suitable temperature from to 320 F. or higher, for instance, depending upon the particular synthetic rubber being dried. The sheet then passes into another chamber where cold air is blown upon the sheet through ducts 05, l05, passes out of the oven, and onto a windup roll. Alternately, the sheet may be festooned and pressed into bales. The product is in the form of a uniform, coherent sheet having a pleasing appearance and is very easily broken down upon a roll mill.

This application is a division of my application Serial No. 442,350, now Patent No. 2,424,648, led May 9, 1942.

I claim: I

l. The method of continuously transforming an aqueous dispersion of a synthetic rubber comprising a polymer of ia butadiene-1,3 into a synthetic rubber sheet which comprises producing from said dispersion an aqueous slurry of discrete synthetic -rubber crumbs of a substantially uniform diameter between about 0.2 mm. and about 1 mm., depositing a uniform layer of the crumbs upon a pervious moving surface, directing upon the moving layer of crumbs a stream of water flowing in substantially the same direction as the movement of the lay-er of crumbs upon the surface so as to wash the individual crumbs without substantially disturbing their relative positions in the moving layer, and to permit the individual crumbs in the layer to cohere to form a porous sheet, applying pressure to the porous sheet on the moving surface sucient to close the pores and form a continuous sheet and then removing the sheet from the moving surface.

2. The method of continuously transforming an aqueous dispersion of a synthetic rubber comprising a polymer of a butadiene-1,3 into a continuous synthetic rubber sheet which comprises producing from said dispersion an aqueous slurry of discrete synthetic rubber crumbs of a substantially uniform diameter between about 0.2 mm. and about 1 mm., depositing a uniform layer of the. crumbs on a; pervious moving surface, di'- rect/ingy upon the moving layer of. crumbs a stream ofY hotlwater flowing with substantially the same velocity and inV substantially the same direction as they movement of the layer of the crumbs upon the surface so as to wash the individual crumbs without substantially disturbing their relative positions in the-moving layer and. to permit the individuali crumbs in thel layer t cohere to form a: poroussheet, applying pressure to the` porous sheet on the moving surf-ace sufhcient to'closc the pores and forma continuous sheet, immediately directing ajet of Coldwater onto the newly formed sheet to producek a, water-containing selfisustaining sheet of substantial strength; removing the sheet fromV the moving surface and dewater'- ingthe sheet.

3; Themethod of continuouslytransformingan aqueous'dispersion of a synthetic rubber comprising a polymer of a butadiene-1,3 into a continuous synthetic rubber sheet which comprises prof ducing. from said dispersion 4anaqueous slurry ofdiscrete synthetic rubber crumbs of ay substantially uniform diameter between about 0.2 mm'. and: about 1 mm., depositing. a uniforinlayer offthe crumbs upon a pervious moving surface, directing upon the moving layer or crumbs a stream of water flowing with substantiallythe same-velocity and in substantially the same direction as themovement ofthe layer of` crumbs upon the surface soasto wash the individual crumbs without substantially disturbing their relative positions in the moving layer andI tov permit the individual crumbs inthe layer to co-here to formthetic rubber crumbs of a substantially uniform' diameter b-etween about 0.2- mm. and about 1 mm., depositing a uniform layer of the crumbs upon a. pervious moving surface, directing upon the moving layer of crumbs a stream of-water flowing in substantially the same direction as the-movement of the layer of crumbs upon the surface so as towash the individual crumbs Without substantially disturbing their relative positions in the moving layer4 and to permit-the individual crumbs in the layer to cohere to form a porous sheet, applying pressure to the porous sheet on the moving surface suihcient toclose the pores and form a continuous sheet, immediately directing a j et of water onto the newly formed sheet to produce a water-containing self-sustaining sheet of substantial strength, removing the sheet' to another less perviousmoving surface and applying pressure to oneside of the sheet andfsuction to the other side'ofl the-sheet te dewater th'esheet` upon the less pervious moving surface;

5. The method o-f-continuously transforming'an aqueous dispersion of a synthetic rubber comprising a polymer of a butadiene-1,3 into a synthetic rubber sheet which comprises producing from said dispersion an aqueous slurry of discrete synthetic rubber crumbs of a substantially uniform diameter between about 0.2 mm. and about 1 mm., de-

positing a uniform layer of the crumbs upon'a pervious moving surface, directing upon the mov-i ing layer of crumbs a streaml of water flowing with substantially the same velocity andv in substantially the same direction as the movement of the layer of crumbs upon the surface so` as to wash the individual crumbs without .substantiallyv disturbing their relative positions in the moving layer and to permit the individual crumbs in thev layer to cohere toform a porous applying pressure to the porous sheet on the moving surface sufiicient tol close the pores and form al continuous sheet, removing the sheet from the moving surface, passing the sheet through a blast of hot air to` dry the sheet and then passing the sheet through a blast of unheated air to cool the" sheet.

6. The method of continuously transforming an aqueous dispersion of a synthetic rubber' comprising a polymer of a` butadiene-1,3 into" afsy'n# thetic rubber sheet which comprises producing from said dispersion an aqueous slurry of discrete synthetic rubber crumbs of a substantially uniform diameter between about 0.2 mm. and aboutv l mm., depositing a uniform layer of the crumbs upon a pervious moving surface, directing upon the movin layer of crumbs a stream of'water .iiowing Wit l substantially/'the sarncvelocit'y and in substantially the same direction as the movef ment of the layer of crumbs upon the surfaceso as t0 wash the individual crumbs without substantially disturbing their relative positions in the moving layer and to permit the individual crumbs in the layer to cohere to form a porous sheet, applying pressure to the porous sheet onr the moving surface suflicient to close the pores'v and form a continuous sheet, immediately direct'- ing a jet ofwater onto the newly formed sheet produce a water-containing self-sustaining sheet of substantial strength, directing' a jet of fluid upon the underside of the sheet through the pervious moving surface momentarily to' raise the sheet from the surface and therebyI prevent permanent adherence thereto, removing the water-containing sheet from the moving surface to another less pervious'moving surface, applying pressure to one side of the sheet and suction to the other side of the sheet, while upon the less pervious moving surface, to dewater' the sheet and then drying the sheet.

7. In a method of continuously transforming an aqueous dispersion of a synthetic rubber comprising a polymer of a butadiene-1,3 into a sheet,l

which method involves'rst producingy fromsaid dispersion an aqueous slurry of discrete synthetic rubber crumbs and then forming the crumbs into a sheet, the steps which comprise' depositing a,`

uniform layer of the crumbs uponv a pervious moving surface, directing'upon the moving layer".

of crumbs a stream of water flowing in substan` tially the same direction asv the movement of the layer of crumbs upon the surface so asl to" washthe individual crumbs without substantially disturbing their relative positions in the moving'v layer and then applying pressure to the crumbs on. the 4movingy surface to vform a continuous synthetic rubber sheet.

8. Apparatus for the continuous ltransforr'naftion of an'aqueous slurry of small discrete rub'- bery particles into a continuous sheet comprising a pervious movable conveyor, means for deositing a uniform layer of the discrete rubbery particles thereon, a liquid delivering element positioned above the conveyor and having a discharge portion disposed substantially tangentially to the conveyor in the direction of movement thereof for applying wash water to the individual particles Without substantially disturbing their relative positions in the layer and a pressure-applying element disposed above the conveyor at a point in its direction of movement beyond that of the liquid delivering element for pressing the Washed particles into a continuous sheet.

9. Apparatus for the continuous transformation of an aqueous slurry oi small discrete rubbery particles into a continuous sheet comprising a travelling wire screen, means for depositing a uniform layer of the discrete rubbery particles thereon, a series of inclines each positioned above the screen and extending at its lower end in a direction substantially horizontal to the screen for applying wash Water to the particles without substantially disturbing their relative positions on the screen, a series of pressure rolls each disposed above the screen at a point in its direction of movement beyond that oi the said series of inclines for pressing the washed partlcles into a continuous sheet and a series of liquid delivering orifices each positioned above the screen at a point in its direction of movement just beyond that of one of the said pressure rolls for flowing a stream of Water onto the sheet as it leaves the roll to increase the strength of the sheet.

10. Apparatus for the continuous transformation of an aqueous slurry of small discrete rubbery particles into a continuous sheet comprising a travelling wire screen, means for depositing a uniform layer oi the discrete rubberyparticles thereon, a liquid delivering element positioned above the conveyor and having a discharge portion disposed substantially tangentially to the conveyor in the direction of movement thereof for applying Wash Water to the individual particles, thereby Washing the particles and permitting the particles to cohere into a porous sheet, an orifice positioned below the screen at a point in its direction of movement beyond the said liquid delivering element for applying additional Wash Water to the underside of the porous sheet, a pressure-applying element disposed above the conveyor at a point still further removed in its direction of movement for pressing the washed particles into a continuous sheet and another liquid delivering orice positioned above the screen at a point in its direction of movement just beyond that of the said pressure-applying element for iiowing a stream of water onto the sheet as it leaves the pressure-applying element so as to increase the strength of the sheet.

11. Apparatus for the continuous transformation of an aqueous slurry of small discrete rubbery particles into a continuous sheet comprising a travelling Wire screen and a travelling napless brous carrier, means for depositing a layer of the discrete rubbery particles upon the travelling wire screen, a liquid delivering element positioned above the screen and having a discharge portion disposed substantially tangentially to the screen in the direction of movement thereof for applying Wash Water to the individual particles without substantially disturbing their relative positions in the layer, a pressure-applying element disposed above the conveyor at a point in its direction of movement beyond that of the liquid delivering element for pressing the Washed particles into a continuous sheet, a liquid delivering orifice positioned above the screen at a point in its direction of movement just beyond that of the said pressure-applying element for flowing a stream of water onto the newly formed sheet to increase the strength of the sheet, means for removing the sheet from the travelling Wire screen onto the travelling napless brous carrier, a pressure element positioned above the fibrous carrier and a suction element positioned below the fibrous carrier at a point beneath that of the said pressure element for dewatering the sheet upon the fibrous carrier.

12. Apparatus for the continuous transformation of an aqueous dispersion of a rubbery material into a sheet comprising a coagulating tank for coagulating the dispersion in a ycrumb-like form, a mechanical disintegrator for reducing the crumbs into a uniform small size, a pervious movable conveyor, means for depositing a uniform layer of the small rubbery crumbs thereon, a liquid delivering element positioned above the conveyor and having a discharge portion disposed tangentially to the conveyor in a direction of movement thereof for applying Wash Water to the individual particles Without substantially disturbing their relative positions in the layer and a pressure-applying element disposed above the conveyor at a point in its direction of movement beyond that of the said liquid delivering element for pressing the washed particles into a continuous sheet.

13. In an apparatus for the continuous transformation of an aqueous dispersion of a rubbery material into a sheet, which apparatus includes means for producing from said dispersion a slurry of small rubbery crumbs and means for drying the rubbery sheet produced from the crumbs, a crumb-Washing and sheet-forming unit including a pervious movable conveyor, means for applying a uniform layer of discrete robbery crumbs thereon, a liquid delivering element p0- sitioned above the conveyor and having a discharge portion disposed substantially tangentially to the conveyor in the direction of movement thereof for applying wash Water to the individualV crumbs Without substantially disturbing their relative positions in the layer and a pressureapplying element disposed above the conveyor at a point in its direction of movement beyond that of the liquid delivering element for pressing the washed crumbs into a continuous sheet. WILLARD F. BIXBY.

REFERENCES CITED The following references are of record in the 

